Designing an Adaptor From Standard to Non-Standard Parts

This guide gives you an explanation on how you can design an adaptor between an standard part and a non-standard part in order to repair/replace a broken part of everyday appliances. Fusion 360 was the CAD software of choice in this guide, but you can use any other 3D modeling program if you want.

Take for example an universal handle that can be placed on a non universal vacuum cleaner bar. If the handle from the vacuum cleaner breaks down, you can adapt any standard handle instead of the specific brand handle. This prevents the user from having to search for the exact original part of a particular brand, and thus also the risk that this particular part is not sold (anymore).

This guide will be going through the steps to create a non-standard to standard part adaptor for the connection between the handle and the shaft of a Vileda Looper electric spray mop. Make sure to adapt the steps taken for your specific repair case!

• Fusion 360 (or any other CAD software)
• Measuring equipment, e.g. rulers, calipers
• Camera

Measure the dimensions of the standard part. In this instance, we used a handle with a standard outer diameter of 32mm, with a wall thickness of 2mm

Download the library (attached in this step) for the connecting standard part and open it in Fusion 360. Copy the right standard shape and paste it in a new document.

Measure the dimensions of the non standard part. In this case, we measured the width and height of this aluminium tube with a non-standard profile. Also measure the distance to the button hole as well as the diameter of the button hole. Finally, measure the thickness of the button itself.

Take a picture of the non universal part from above. Try to make sure to be in line with the part as possible to avoid parallax (perspective shift) of the side profile. An alternate method for flat profiles that can work depending on the size of the part is to directly place the part on a document scanner.

Import the picture in Fusion 360 by clicking on Insert > Canvas > Insert from my computer and then select the picture made in Step 4.

Create a sketch and trace the inside and outside shape of the non-standard part.

Extrude the lines to make it a 3D shape.

Make a loft between the two extrusions at the bottom and the top.

Stitch the 4 bodies together. This will make it a closed body instead of an open one.

Scale the shape to the correct dimensions, which was measured in Step 3.

If the part is connected with a snap-fit connection follow Steps 11 - 15, if not go to Step 16.

Draw the dimensions measured in Step 3 in the sketch with the line and circle tool under Solid > Create tab > Line or Circle.

Create the cylinder in the right dimensions with the cylinder tool under Solid > Create > Cylinder.

Draw the sketch of the slot.

Extrude the lines of the slot under solid > extrude to make the hole.

Import the right shape in the file downloaded in Step 2. You can import the shape through Insert > Insert derive, then click on the library document and double click on the right shape. The shape will now be imported to your document.

Measure the angle in the original product.

Place the universal and non universal part in the right angle. Select the body > Move/copy > select Rotate > insert 120 degrees > move object to the right place.

Attach the two parts to each other Using the loft tool found in Surface > Loft. Loft the inside shapes and the outside shapes separately from each other.

Done! Now you can print your part and use it to repair your broken electronics.